Imitation grass mat



May l2, 1936. G. J. KADERBECK 2,040,511

IMITATION GRASS MAT Filed Sept. 19, 1953 2 Sheets-SheetKl May 12, 1936. G. J. KADL- RBECK IMITATION GRASS MAT Filed sept. 19, 19:55

2 Sheets-Sheet 2 d, l' la f'ozye mrgeci' Patented May '12, 1.936

IMITATION GRASS MAT George J. Kaderbeck, Hamburg, N. Y., assignor, by direct and mesne assignments, of one-half to Hamburg Floral Mfg. C0., Inc., Hamburg, N. Y., a corporation of New York, and one-half to The Joseph M. Stern Company, Cleveland, Ohio, a corporation of Ohio Application September 19, 1933, Serial No. 690,119

22 Claims.

My invention relates to imitation grass mats of the type now in common use for decorative purposes, such as used at indoor flower shows; for displaying outdoor furniture; for covering mounds of soil dug from graves; for concealing the soil in graves, and for various other pur- DOSSS.

Imitation grass mats of this kind are commonly made of raia and various methods are employed to arrange the raia on and sew it or otherwise apply it to a suitable flexible foundation, such as burlap, with a view of 'having the railia stand upright from the burlap or other foundation and simulate natural grass.

Railia commonly used for this purpose is commercially sold in hanks or skeins, the strands of rafla being tied together at one end of the hank or skein and being twisted for convenience in handling and shipping and also with a view of maintaining the strands in untangled condition.

`However, by reason of the twist given these strands of rafla it is necessary to straighten them so as to eliminate the twist, since it is highly desirable that these strands be substantially straight in order that they may be arranged in regular order and severed in desired lengths, the severed short lengths being sewed or otherwise fastened to the burlap or other flexible foundation midway between their ends and shaken or otherwise treated so that the portions at opposite sides of the stitching are directed upwardly away from the burlap or other foundation so as to simulate blades of grass rising from the soil.

Since rafiia has a dull gray appearance in its commercial state, it i's dyed by giving it a shade of green in any approved manner, approaching that of grass, and it is also necessary, under present methods of4 manufacture, to dye the burlap or other exible foundation a similar color or shade, especially since, after considerable usage,

the moisture in the raia, provided by dyeing the same, evaporates and when used exteriorly this evaporation is considerably augmented by air and the sun, with the result that the short lengths of rail-la at opposite sides of the line of stitching curl upwardly more than intended or desired and expose portions of the burlap or other flexible foundation to which it is applied. In this condition the mat loses its attractiveness, and no longer is a simulation of natural grass provided.

Imitation grass mats as now constructed, even when new, expose the burlap or other flexible foundation when laying the same on an uneven, and especially convex, surface, such as a mound of soil adjacent a grave this exposure being caused by the separation of the rows of short lengths of raia sewed to the foundation.

It is the object of my invention to provide an imitation grass mat which will not expose the burlap or other foundation of the mat when the rows of short lengths of raa stitched to the burlap or other flexible foundation curls up due to the Tania having become dry, or when the mat is used to walk upon and the rows of short lengths of rafiia become Worn.

Another object of my invention is to provide an imitation grass mat which will have added length of life, even though the regularly applied rows of short lengths of raflia curl up, or become worn away by reason of using it as a mat to be walked upon. v

A further object of my invention isthe utilization of waste raffia, such as caused by the combing or shredding of the hanks or skeins of raia with a view of vstraightening out the strands; such combing or shredding resulting in separating or looseningvarious lengths of raiia, which have heretofore been considered unusable.

Under my improved method I employ such waste for an under or sub-layer,.the ends of the various lengths or strands so used curling up where space is allowed and filling the voids between the regular. rows of raa used as the surfacing or exposed layer.

With the above and other objects to appear hereinafter my invention consists in providing the burlap or other flexible foundation with a sub-layer of raftia, preferably so as to completely cover the foundation, and in applying short lengths of raflia to the so covered foundation.

My invention further consists in the novel method of manufacturing imitation grass mats to be hereinafter described and pointed out in the appended claims.

In the drawings:

Fig. 1 is a perspective view of the burlap 0r other flexible foundation of a mat, showing the same provided with a covering in the form of a sub-layer of rafiia, the sub-layer being removed at one corner to disclose the burlap or other exible foundation. Y

Fig. 2 is a perspective view of a retainer for retaining short lengths of railia, in regular order, preparatory to sewing the same to the rathacovered burlap. v

Fig. 3 is a perspective view of a mat in the course of construction, showing the foundationA provided with the sub-layer of raflia, one row of short lengths of raflia sewed or otherwise applied thereto, and another row of short lengths of CII raflia arranged to be sewed or otherwise applied by means of the retainer shown in Fig. 2.

it is clamped between retainers, such as shown` in the drawings, or otherwise, and out to desired short lengths so that portions project evenly from opposite sides of the retainers. With suitable waste at hand and a piece of burlap or other flexible material of the desired size, all material to construct the mat according to my invention will be at hand.

In the drawings the reference numeral 'I designates the burlap or other material used as a flexible foundation for the mat. 8 designates the waste rairia, which is in such condition that some strands are twisted, others curled, and still others more or less straight-lined, and this waste rafa is placed in roughly assembled form over the burlap or other flexible foundation by spreading it evenly without any attempt to lay or press the end portions` of the numerous strands of rafla down against the flexible foundation, ,such end portions being permitted to retain their natural condition, with the result that many of these ends stand upwardly and project away from the ilexible foundation, which is a desirable feature of my invention, although not absolutely necessary. The waste raflia thus applied is basted by long stitches or otherwise to the flexible foundation, as indicated by the numeral 9 inFigs. l and 3. This waste ,raflia thus forms a sub-layer which `fully conceals the burlap or other flexible foundation, and has most of the end portions of its strands free, and many projecting vupwardly Where unbasted. This sub-layer therefore has a more or less grassy appearance, although not one simulating a mowed lawn.

The numeral I designates a retainer in which the straight-lined rafla is clamped by placing it transversely to the length of the retainer and in a layer of the desired thickness. The raa is then cut along opposite sides of the retainer to provide short parallel lengths, as shown at I I, and in this form each retainer, with the raflia clasped therein, is placed upon the sub-layer of rama basted to the foundation and sewed by running the needle of a sewing machine through the slot I2 in the retainer. The substantially straightlined short lengths of raflia are therefore sewed to the rama-covered foundation, as indicated at I3, Figs. and 6, after which the upper member I4 of the retainer is removed from the lower member I5 thereof and the lower member slid laterally from underneath the applied row of railia. The rafiia, when released from the retainer, curls upwardly, as indicated along the upper edge in Fig. 3, or as indicated over the entire surface of the mat shown in Fig. 4; and itis then roughened with the hands, or otherwise agitated or ruffled to aid in directing the ends of the short lengths of rafa upwardly to simulate the blades of grass of a mowed lawn.

As clearly shown in Figs. 3, 5 and 6, the strands of raifia which provide the grassy-like surface for the mat, are preferably disposed at right angles to the direction of the waste raa forming the sub-layer.

As clearly shown in Fig. 6 the rows of short length railia are curved or directed upwardly and provide spaces between the rows along their lower regions directly above the sub-layer of raia. The ends of the short strands of raflia. of adjoining rows lie in contact with each other and intermingle somewhat along their marginal portions so that when the mat lies flat,v the ends of the short lengths of strands, may be referred to as the surface layer of rafia, appear lto rise in straight lines from the foundation and thus simulate the blades of grass rising in straight lines from the soil.

It is to be noted that many of the ends of the strands of waste raflia forming the sub-layer project upwardly into the spaces between the rows of rafa forming the surface layer, as'indicated at I 6, Fig. 6; some of these ends rising to a height even with that of the raifia of the surface layer while others.extend upwardlyA various distances. l

When the surface layer becomes worn, or when the raia becomes dry after a long period of use and curls up so that the adjacent rows are reduced in width and spaces provided along the upper surface of the mat between the rows of raffia, the raffia forming the sub-layer will be exposed.

The mat will retain its grassy appearance even though the rafa of the surface layer becomes completely dried, and in this connection it may be stated that when dyeing the mat, a chemical 0r other substance is employed which tends to keep the raflia moist and attract moisture to the raila so that it will retain a fresh grassy appearance for a considerable length of time. However, lexL posure to the sunor to dry air, will eventually result in completely drying the raia of the upper layer and cause it to curl so that therows of raia forming the surface layer become separated. Even under such conditions, no portion of the coarse woven burlap will be exposed, since the rafa forming the sub-layer fully covers the same, and especially since the upstanding free ends of the strands of said sub-layer effectively fill the gaps between the rows so formed, even though along regions thereof a lower level for the mat will be provided than that provided by the rafiia forming the surface layer. A pleasing effect is retained for the mat, especially since the sublayer will not have become dried o ut to the extent of the surface layer. This will assure a grassy appearance over the entire surface of the mat for a considerable length of time, thus providing a useful life for the mat doubling that of a mat formed in the ordinary manner.

Having described the construction of my improved mat in conjunction with the method of making the same, I do not consider it necessary to separately describe the method of constructing the mat, but wish to state that the retainers and the method of applying and securing the rows of rama forming the surface layer of the mat are merely representative, and that such surface layer may be otherwise applied; and, furthermore, that it is not essential that the waste railia be arranged with its numerous strands in more or less parallel relation since, broadly considered, the use of a sub-layer of raa, whether formed of waste material or otherwise, falls fully within the scope of my invention as defined in the appended claims, regardless of its mode of application to the foundation; it being the purpose of my invention to cover those portions of the burlap or flexible foundation which would be exposed when the rows of raiia forming the surface layer become separated, whether due to the wearing of such surface layer, to the drying of the raa, or the placing of the mat upon a convex or similar surface in which the foundation of the mat would be exed and the rows of raflia forming the surface layer separated to expose portions beneath. Moreover, it is not my intention to limit myself to the use of rafa, and when in the claims this term is employed, it is intended to include any fibrous or other strand-like material capable of use in the manner herein described.

I prefer to construct the mat completely while the several parts including the same are in their natural color and condition, and then dye the same to vthe desired color or shade, preferably green to simulate a mowed lawn;

By the term layer, as used in the claims, I mean covering material formed of numerous strands or fibres formed in rows or assembled and spread out over the entire area or definite areas of the foundation, or backing as it may be termed; the covering material consisting preferably of strands or fibres of raflia in superimposed layers applied to a suitable foundation or backing, with one layer arranged over the other in any suitable manner so long as the numerous strands or fibres forming the lower or sub-layer are re- -tained in place on the foundation or backing after applying the numerous short strands forming the upper or surface layer in regular rows; and it is to be understood that the relative disposition and regularity of the two layers of strands or bres is immaterial so long as strands or fibres of the lower or sub-layer become exposed when the strands or fibres of the upper or surface layer separate at or along any region of the mat.

Having thus described my invention, what Il claim is:

1. An imitation grass mat, comprising a flexible foundation, a layer of imitation grass material on said foundation to substantially cover the same, said imitation grass material having upwardly-directed free end portions, anda second layer of like material applied over said rst layer and formed of rows of short lengths of material arranged to have the end portions of each row extending upwardly to simulate blades of grass and to have theend portions of adjoining rows in contact with each other to normally expose only the material of said second layer.

2. An imitation grass mat, comprising a flexible foundation, various lengths of imitation grass material laid substantially fiat vupon said foundation, and short parallel strands of imitation grass material arranged in rows and fastened between the ends of said short strands to provide upstanding end portions for said short strands simulating blades of grass, the material of adjoining rows being in contact to conceal the substantially flat imitation grass material beneath until from any cause the material in one of said rows of short parallel strands is separated from the matelrial of an adjoining row.

3. An imitation grass mat, comprising a flexible foundation, a layer of waste imitation grass material on said foundation and secured thereto, s'aid material having free end portions projecting upwardly from said foundation in irregular order, and a second layer of grass material arranged over the first-mentioned layer in regular order to simulate blades of grass and form a surfacing layer which under normal conditions substantially conceals the first-mentioned layer of imitation grass material, said first-mentioned layer being exposed only when the material of said surfacing layer separates at or along any region.

4. An imitation grass mat, comprising a exibl foundation, a layer of imitation grass material applied to said foundation and basted thereto, and a surfacing layer of imitation grass material applied to said first-mentioned layer and comprising rows of short lengths of grass material grouped in regular order transversely with respect to the trend of said rows and stitched in place lengthwise of said rows between the ends of said short lengths of material to form opposite free end portions for each row which are directed upwardly to simulate blades of grass, the material of adjoining rows lying in contact and when separating at any region exposing the material in said first-mentioned layer.

5. An imitation grass mat, comprising a flat and be exposed when the material of adjoining rows of said surface layer becomes separated.

6. An'imitation grass mat, comprising a ilexible foundation, a layer of waste rai-lia disposed over said foundation to substantially cover the same and to allow free ends of strands of raffa to assume any natural free condition, and parallel rows of short lengths of raflia grouped-together in parallel order over said layer of waste raiia transversely to the trend of the rows of rafa and sewed approximately midway between the ends of said short lengths to the raiacovered foundation so as to provide free portions for the short lengths of rafliaof each row and permit said free portions to extend upwardly and simulate blades of grass, said upwardly extending free end portions providing spaces beneath the surface of the mat and between adjoining rows thereof into which free end portions of the first-mentioned layer of raffla extend.

.said foundation arranged to allow end portions of said various lengths to assume various positions in free condition, asurface layer of raa applied over the so raia-covered foundation formed of parallel rows of short lengths of raflia regularly grouped with the short lengths trending at right angles to the-trend of said parallel rows, said rows being sewed to the said foundation between the ends of said short lengths of raflia to providefree end portions curved upwardly to simulate blades of grass and to provide spaces between the rows in regions below the upper surfaces thereof into which free ends of the first-mentioned layer of raa extend, said lastmentioned raflia being exposed when end portions of said short lengths of raa forming said parallel rows become worn, or when said short lengths of raia become sufficiently dry to curl inwardly toward the plane of stitching of said parallel rows to said foundation. y

8. The method of constructing imitation grass mats, which consists in 4applying substantially flat imitation grass material to one side of a fiat foundation so as to substantially cover said foundation and in fastening over the so covered foundation short lengths of rafa having end portions extending upwardly from said sideof the foundation to provide opposite end portions for said I short lengths directed -in an upward manner to simulate blades of grass.

10. The method of constructing imitation grass mats, which consists in distributing rafiia over the entire surface of a exiblejfoundation and fastening the rafa thereto so that end portions l of the strands of raflia are free and may project upwardly from said flexible foundation, in then sewing rows of short parallel lengths-of raflia uniformly grouped over the so covered foundation to provide upstanding end portions simulating blades of grass with rama of each row lying in contact with raflia of an adjoining row to ex- Apose only the raffia of the various rows.

of raiiia grouped in parallel arrangement to `.provide free upwardly-directed portions at oplposite sides of the stitching with raiiia of adjoining rowsin contact andY with end portions of the raftia first applied to said foundation extendling irregularly upwardly into spaces between said parallel rows, andl in then dyeing the mat so completed to desired shade or color, whereby a mat is provided in which the foundation is concealed when the short lengths of raflia separate between rows.

12. -The method of constructing imitation grass mats, which consists in applying a layer of raflia to a iiexible foundation, in clamping uniform short lengths of raia in substantially parallel arrangement within retainers, in applying the -retai'ners with the so clamped short lengths o f raia onto said layer of rafiia, and in sewing the vsaid short lengths of raflia to the foundation over said layer of raffia and removing said retainers from the short lengths of raflia so as to provide free upwardly-directed portions for the raa at opposite sides of the stitching, with end portions ofraina of adjoining rows in Contact and with end portions of the layer of raflia first applied to said foundation-extending irregularly upwardly into spaces between said rows ofraiiia.

13. The method of constructing imitation grass mats, which consists in applying raflia to a flexible foundation, in clamping short uniform lengths of raffia in substantially parallel arrangement Within retainers, in successively applying the retainers with the so clamped short lengths of rafiia onto the so covered foundation, and in then sewing the said short lengths of raffia to the so covered foundation and removing said retainers from the short lengths of raliia so as to providel free upwardly-directed portions for the raflia at opposite sides .of the stitching with rafiia of adjoining rows in contactI at the free upper ends so that the rafliarst applied to said foundation becomes exposed when the raiiia of adjoining rows separate.

14. An imitation grass mat, comprising afount vdation, a layer of imitation grass material on one side of said foundation having free end portions, and a surfacing layer of imitation grass material over and fastened to said first-mentioned layer to simulate a layer of grassl normally concealing said first-mentioned layer, said firstl mentioned layer having free end portions extending upwardly` between the imitation grass material of said surfacing layer and becoming exposed at any point of said mat at which the grass material of the surfacing layei` separates.

15. An imitat-ion grass mat, comprising a flexible foundation, a layer of imitation grass material on said foundation, and a surfacing layer of imitation grassmaterial arranged over4 said first-mentioned layer and comprising rows of short lengths of grass material grouped in regular order transversely with respect to the trend of said rows and stitched. in place lengthwise of said rows between the ends of said short lengths of material to form free opposite end portions for each row which are directed upwardly to simulate blades of grass, the material of adjoining rows lying in contact and when separating at any region exposing the material in said rstmentioned layer.

16. An imitation grass mat,pcomprising a iiexible foundation, a layer of waste imitation grass material placed on one sideof said foundation and having short free end portions projecting upwardly from said foundation, and a second layer of imitation grass material applied to said first-mentioned layer so as to extend upwardly from said foundation and simulate blades of I grass, said second layer forming a surfacing layer which substantially conceals said first-mentioned layer of imitation grass material and said firstmentioned layer `having free end portions extending upwardly into said second layer and being exposed only. when said surfacing material separates at or along any region.

17. An imitation grass mat, comprising a flexible foundation, a substantially flat layer of imitation grass material on one side of said foundation, and 'a surfacing layer of imitation grass material applied to said first-mentioned layer and comprising rows of short lengths of grass material grouped in regular order transversely with respect to the trend of said rows and stitched in f place to form upwardly-directed portions simulating blades of grass, the short lengths of grass material of adjoining rows lying in contact and when separating at any region exposing said firstmentioned layer of grass material, said firstmentioned material -concealing said foundation at such region of separation.

18. Animitation grass mat, comprising a fiexible foundation, imitation grass material in strand or fibre form and of irregular lengths laid sub- I..

stantially fiat upon said foundation, and rows of short lengths of imitation grass material stitched to said foundation between the ends of said short lengths and normally concealing said irregular lengths of strands or fibres, said irregular lengths of strands or fibres being exposed to the eye only when said parallel'rows of short lengths of imitation grass material or any portion of adjacen rows become separated. 19. An imitation grass mat, comprising a flexible foundation, and imitation grass material on one side thereof comprising two superimposed layers of assembled strands of grass material, the n strands of each having upwardly-directed free end portions, said layers being so arranged that when the upper layer separates at any point the lower layer becomes exposed.

20. An imitation grass mat, comprising a ilexible foundation, and two superimposed layers`of accom i assembled strands or imitation grass material on one side oi said foundation substantially covering the same, each of said layers having upwardly-extending free end portions and one of said layers only being exposed when said flexible foundation is in fiat condition and the other when said last-mentioned layer separates upon Bening of said foundation or when worn away at any sur` face region or regions.

2i. An imitation grass mat, comprising a nexible foundation, and two superimposed layers of imitation grass material on said foundation, the grass material of eaciiy of said layers having upwardiy-directed iree'end portions, the upper oi C said layers only being exposed and conceaiing the lower and said lower becoming exposed only along regions when the upper layer is separated due to wear, exposure, or upon flexing of the mat.

22. An imitation grass mat, comprising a. exible foundation and imitation grass material composed oi' two superimposed layers of assem-7 l bled strands of such material, the strands of each` layer having free ended upstanding portions simulating blades of grass and one of said layers normally concealing the iibers oi the other layer, and when separated at any point or region exposing said other layer to conceal said foundation at the separated point or region.. 

